Systems and methods for making and using improved connector contacts for electrical stimulation systems

Abstract

A connector for an implantable electrical medical device includes a connector lumen defined in an elongated connector housing and adapted for receiving a portion of a lead. Connector-contact assemblies are disposed in the connector lumen and adapted to couple to terminals of the lead when the lead is received by the connector lumen. Each of the connector-contact assemblies includes a contact body. An inner surface of the contact body defines an open center portion. A first base is disposed along a first end of the contact body, and a second base is disposed along an opposing second end of the contact body and is coupled to the first base. Biasing members are attached to the first base and extend towards the second base. The biasing members are not attached to the second base. When the lead is received by the connector lumen the biasing members physically contact the received lead.

What is claimed as new and desired to be protected by Letters Patent of the United States is: 
     
         1 . A connector for an implantable electrical medical device, the connector comprising:
 an elongated connector housing having a first end and an opposing second end;   a connector lumen defined in the connector housing, the connector lumen configured and arranged for receiving a proximal portion of a lead or lead extension;   a plurality of connector-contact assemblies disposed in the connector housing, each of the plurality of connector-contact assemblies comprising
 a contact housing having a first end portion, a second end portion, an inner surface, and an outer surface, the inner surface of the contact housing defining an open center portion having a circumference, the open center portion of the contact housing forming a portion of the connector lumen, the open center portion having a first inner diameter along the first end portion and a second inner diameter along the second end portion, wherein the second inner diameter is larger than the first inner diameter, 
 a connector contact disposed in the open center portion of the contact housing, the connector contact comprising a first base disposed along, and in contact with, the first end portion of the contact housing and around the circumference of the open center portion of the contact housing, a second base disposed along the second end portion of the contact housing and around the circumference of the open center portion of the contact housing, and a plurality of biasing members extending along the inner surface of the contact housing and attaching the first base to the second base, wherein when the proximal portion of the lead or lead extension is received by the connector lumen the plurality of biasing members physically contact the received lead or lead extension; and 
   a plurality of connector conductors coupled to the plurality of connector-contact assemblies and extending along the connector housing.   
     
     
         2 . The connector of  claim 1  wherein, for each of the plurality of connector-contact assemblies, the plurality of biasing members extend along an entire length of the open center portion of the contact housing. 
     
     
         3 . The connector of  claim 1  wherein, for each of the plurality of connector-contact assemblies, the plurality of biasing members each comprise at least one bend that extends into the open center portion of the contact housing and that narrows the inner diameter of the open center portion. 
     
     
         4 . The connector of  claim 1  wherein, for the each of the plurality of connector-contact assemblies, the contact housing is electrically coupled to the connector housing. 
     
     
         5 . A lead assembly comprising:
 a lead comprising
 a lead body with a proximal portion, a distal portion, and a longitudinal length, 
 a plurality of electrodes disposed on the distal portion of the lead body, 
 a plurality of terminals disposed on the proximal portion of the lead body, and 
 a plurality of lead conductors electrically coupling the plurality of electrodes to the plurality of terminals; 
   a lead extension having a proximal portion and a distal portion; and   the connector of  claim 1  disposed along the distal portion of the lead extension;   wherein the proximal portion of the lead body is configured and arranged for insertion into the connector lumen of the connector.   
     
     
         6 . An electrical stimulating system comprising:
 the lead assembly of  claim 5 ; and   a control module coupleable to the proximal portion of the lead extension of the lead assembly, the control module comprising
 a housing, and 
 an electronic subassembly disposed in the housing. 
   
     
     
         7 . An electrical stimulating system comprising:
 a lead comprising
 a lead body with a proximal portion, a distal portion, and a longitudinal length, 
 a plurality of electrodes disposed along the distal portion of the lead body, 
 a plurality of terminals disposed along the proximal portion of the lead body, and 
 a plurality of lead conductors electrically coupling the plurality of electrodes to the plurality of terminals; 
   a control module electrically coupleable to the lead, the control module comprising
 a housing, and 
 an electronic subassembly disposed in the housing; and 
   the connector of  claim 1  coupled directly to the control module;   wherein the proximal portion of the lead body is configured and arranged for insertion into the connector lumen of the connector.   
     
     
         8 . A connector for an implantable electrical medical device, the connector comprising:
 an elongated connector housing having a first end and an opposing second end;   a connector lumen defined in the connector housing, the connector lumen configured and arranged for receiving a proximal portion of a lead or lead extension;   a plurality of connector-contact assemblies disposed in the connector housing, each of the plurality of connector-contact assemblies comprising
 a contact housing having a first end, an opposing second end, a longitudinal length, an inner surface, and an outer surface, the inner surface of the contact housing defining an open center portion having an inner diameter, the open center portion of the contact housing forming a portion of the connector lumen, and 
 a connector contact disposed in the open center portion of the contact housing, the connector contact comprising a plurality of biasing members extending longitudinally outwardly away from the first end of the contact housing and bending back around and into the open center portion of the contact housing, wherein when the proximal portion of the lead or lead extension is received by the connector lumen the plurality of biasing members physically contact the received lead or lead extension; and 
   a plurality of connector conductors coupled to the plurality of connector-contact assemblies and extending along the connector housing.   
     
     
         9 . The connector of  claim 8  wherein, for each of the plurality of connector-contact assemblies, the contact housing and the corresponding connector contact are formed entirely from a single piece of electrically-conductive material. 
     
     
         10 . The connector of  claim 8  wherein, for each of the plurality of connector-contact assemblies, the plurality of biasing members extend along an entire length of the open center portion of the contact housing. 
     
     
         11 . The connector of  claim 8  wherein, for each of the plurality of connector-contact assemblies, the plurality of biasing members each comprise at least one bend that extends into the open center portion of the contact housing and that narrows the inner diameter of the open center portion. 
     
     
         12 . The connector of  claim 8  wherein, for the each of the plurality of connector-contact assemblies, the contact housing is electrically coupled to the connector housing. 
     
     
         13 . A lead assembly comprising:
 a lead comprising
 a lead body with a proximal portion, a distal portion, and a longitudinal length, 
 a plurality of electrodes disposed on the distal portion of the lead body, 
 a plurality of terminals disposed on the proximal portion of the lead body, and 
 a plurality of lead conductors electrically coupling the plurality of electrodes to the plurality of terminals; 
   a lead extension having a proximal portion and a distal portion; and   the connector of  claim 8  disposed along the distal portion of the lead extension;   wherein the proximal portion of the lead body is configured and arranged for insertion into the connector lumen of the connector.   
     
     
         14 . An electrical stimulating system comprising:
 a lead comprising
 a lead body with a proximal portion, a distal portion, and a longitudinal length, 
 a plurality of electrodes disposed along the distal portion of the lead body, 
 a plurality of terminals disposed along the proximal portion of the lead body, and 
 a plurality of lead conductors electrically coupling the plurality of electrodes to the plurality of terminals; 
   a control module electrically coupleable to the lead, the control module comprising
 a housing, and 
 an electronic subassembly disposed in the housing; and 
   the connector of  claim 8  coupled directly to the control module;   wherein the proximal portion of the lead body is configured and arranged for insertion into the connector lumen of the connector.   
     
     
         15 . A method of forming a connector-contact assembly for the connector of  claim 1 , the method comprising:
 cutting the contact housing and a pre-connector contact from electrically-conductive tubing, the contact housing defining an open center portion, the pre-connector contact comprising a plurality of biasing members;   bending the biasing members of the pre-connector contact to form the connector contact; and   inserting the connector contact into the open center portion of the contact housing.   
     
     
         16 . The method of  claim 15 , wherein bending the biasing members of the pre-connector contact to form a connector contact comprises forming at least one bend that narrows an inner diameter of the open center portion when the connector contact is inserted into the open center portion of the contact housing. 
     
     
         17 . The method of  claim 15 , wherein inserting the connector contact into the contact lumen of the contact housing comprises pressing the connector contact into the contact lumen of the contact housing. 
     
     
         18 . The method of  claim 15 , wherein inserting the connector contact into an open center portion of the contact housing comprises maintaining the connector contact within the open center portion of the contact housing solely by an interference fit. 
     
     
         19 . The method of  claim 15 , further comprising at least one of welding or adhesively-affixing the connector contact to the contact housing. 
     
     
         20 . The method of  claim 15 , further comprising inserting the connector-contact assembly into a connector of an implantable electrical stimulation system.